U.S. patent number 5,906,290 [Application Number 08/593,395] was granted by the patent office on 1999-05-25 for insulated container.
Invention is credited to Robert W. Haberkorn.
United States Patent |
5,906,290 |
Haberkorn |
May 25, 1999 |
Insulated container
Abstract
A insulated container adapted for insulating temperature
sensitive contents from the surrounding environment. The container
can have: a body including a sidewall section, a top section and a
bottom section having at least one of an open-top and open-wall;
sidewall; a door pivotably connected to the body for providing an
open position for loading and unloading and a closed position for
insulating contents therin, defining an enclosure; and a
temperature control floater for sealing temperatures in the
enclosure and/or deviding the enclosure into two individual
comartments, connectable to the body.
Inventors: |
Haberkorn; Robert W. (Orland
Park, IL) |
Family
ID: |
24374529 |
Appl.
No.: |
08/593,395 |
Filed: |
January 29, 1996 |
Current U.S.
Class: |
220/505; 190/110;
220/592.19; 220/592.09 |
Current CPC
Class: |
B65D
81/3886 (20130101) |
Current International
Class: |
B65D
81/38 (20060101); B65D 085/38 () |
Field of
Search: |
;220/503,505,528,529,592.09,592.19,59.23 ;180/113 ;190/110 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Moy; Joseph M.
Claims
What is claimed is:
1. A insulated container adapted for insulating temperature
sensitive contents from the surrounding environment,
comprising:
a body including a sidewall section, a top section and a bottom
section having an open-top;
a door pivotably connected to the body for providing an open
position for loading and unloading and a closed position for
insulating contents therin, defining an enclosure, the body and
door include an interior portion, an exterior portion and an
insulative portion; and
a floater substantially complementarily configured to be received
in the body for at least one of sealing temperatures in the
enclosure and deviding the enclosure into at least two
compartments, couplable to the body, the floater comprises at least
one of a passive structure defining an additional insulation layer
and an active structure providing a temperature source.
2. The insulated container of claim 1, wherein the body in
proximity to the open-top includes an outwardly facing
interconnectable structure and the door includes a flap section
attached to at least a portion of an outer periphery of the door
having an inner portion having an inwardly facing interconnectable
structure, interconnectable with the outwardly facing
interconnectable structure of the body.
3. The insulated container of claim 2, wherein the inwardly and
outwardly facing interconnectable structures comprises strips of
Velcro.
4. The insulated container of claim 2, wherein at least one of the
inwardly and outwardly facing interconnectable structures include
rigidizers.
5. The insulated container of claim 1, wherein the floater includes
an internal rigidizer.
6. The insulated container of claim 1, wherein peripheral portions
of the door, sidewall and bottom section are bound.
7. The insulated container of claim 1, wherein the floater is
pivotably couplable to the body.
8. The insulated container of claim 1, wherein the floater is
detachably couplable to the body.
9. The insulated container of claim 1, wherein the body includes
reinforcement sections at least partially around the body and
handles connected thereto.
10. The insulated container of claim 1, wherein the body includes
reinforcement sections at least partially around the body and
handles connected thereto, the handles including adjustable
carrying straps including an extended position providing dual
shoulder straps and a retracted position adapted to provide
independent handles.
11. A insulated container adapted for insulating temperature
sensitive contents from the surrounding environment,
comprising:
a body including a sidewall section, a top section and a bottom
section having an open-top;
a door pivotably connected to the body for providing an open
position for loading and unloading and a closed position for
insulating contents therin, defining an enclosure, the body and
door include an interior portion, an exterior portion and an
insulative portion;
a floater for at least one of sealing temperatures in the enclosure
and deviding the enclosure into at least two compartments,
couplable to the body, the floater is at least one of a passive
structure defining an additional insulation layer and an active
structure providing a temperature source;
the interior and exterior layers having a coating of at least one
of polypropylene and polyester;
the insulative portion comprising a batt of staple fibers being
sandwiched between inside sides of the interior and exterior
layers; and
a binding structure along perimeter edges of the interior and
exterior layers securing the insulative portion therebetween.
12. The insulated container of claim 11, wherein the batt of staple
fibers comprises a layer of at least one of spun bonded material
and Hallofil.
13. The insulated container of claim 11, wherein the interior and
exterior layers comprise a coated, spun bonded material, the
coating comprising at least one of polypropylene and polyester.
14. The insulated container of claim 11, wherein the interior and
exterior layers comprise at least one layer of Mylar, Nylon,
polyester and Vinyl.
15. The insulated container of claim 11, wherein between the
insulative portion and the interior and exterior layers are
intermediate layers of a spun bonded material, defining at least a
five layer construction.
16. The insulated container of claim 11, wherein the insulative
portion comprises one or more layers of a spun bonded material and
one or more layers of a polyester Hallofil material.
17. The insulated container of claim 11, wherein the batt of staple
fibers includes a substantially intimate blend of fibers with a
substantially consistant and uniform density.
18. The insulated container of claim 11, wherein the body and door
include a self-inflatable and substantially springy insulation
layer.
Description
FIELD OF THE INVENTION
This invention relates to insulated quilts, and particularly to an
insulated container.
BACKGROUND OF THE INVENTION
There is a need to insulate and provide minimal temperature
variations to temperature sensitive materials. A drum, keg or
insulative quilt that could provide a secure and tight fit around a
drum of temperature sensitive material would be considered an
improvement. An insulative quilt, and light weight and portable
container that would provide an insulation air pocket and barrier
for minimal temperature loss for the temperature sensitive material
or exposure to the outside environment, and further would be self
inflatable, would be considered an improvement in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a drum quilt in use, substantially
insulating temperature sensitive goods in a drum, shown being
transported on a drum hand truck, in accordance with the present
invention;
FIG. 2 is a front elevational view of the drum quilt shown in FIG.
1, with an interconnectable structure, in accordance with the
present invention;
FIG. 3 is a top plan view of the drum quilt shown in FIG. 1, with a
drum strap and window, in accordance with the present
invention;
FIG. 4 is a top plan view of an embodiment of the drum quilt shown
in FIG. 1, with an interconnectable structure (not shown
interconnected) and with a reinforced area surrounding a slit
adapted to receive a hook section of a drum hand truck, in
accordance with the present invention;
FIG. 5 is a bottom plan view of the drum quilt shown in FIG. 1,
with pull down straps adapted to facilitate placement over a drum,
in accordance with the present invention;
FIG. 6 is a partial side sectional view of the drum quilt shown in
FIG. 1, with a slit with a drum hook inserted therein and
therethrough, in accordance with the present invention;
FIG. 7 is a partial enlarged plan cross section of the drum quilt
taken from FIG. 4, with a vertical binding and interconnectable
structure shown in a disconnected position, in accordance with the
present invention;
FIG. 8 is a perspective view of an alternate embodiment of a drum
quilt with a side opening and interconnectable structure, shown in
an open position, in accordance with the present invention;
FIG. 9 is a front side view of a preferred embodiment of a drum
quilt with an interconnectable structure including adjustable
securement straps and rings, in accordance with the present
invention;
FIG. 10 is a top plan view of the drum quilt shown in FIG. 9, with
a top slit, central seam and window, in accordance with the present
invention;
FIG. 11 is a sectional view of a bottom portion for use in
connection with the drum quilt, in accordance with the present
invention;
FIG. 12 is a partial side sectional view of an embodiment of the
drum quilt shown in FIG. 1 and an insulative quilt, with a three
layer body, in accordance with the present invention;
FIG. 13 is a partial side sectional view of an embodiment of the
drum quilt shown in FIG. 1 and an insulative quilt, with a five
layer body, in accordance with the present invention;
FIG. 14 is a partial side sectional view of an embodiment of the
drum quilt shown in FIG. 1 and an insulative quilt, with a seven
layer body, in accordance with the present invention;
FIG. 15 is a partial side sectional view of an embodiment of the
drum quilt shown in FIGS. 1, 9, 13 and 14 and an insulative quilt,
with preferred five (on the left) and seven layer bodys (on the
right), in accordance with the present invention;
FIG. 16 is a perspective view of a keg quilt in use, insulating
goods in a keg, in accordance with the present invention;
FIG. 17 is a top plan view of the keg quilt shown in FIG. 16, in
accordance with the present invention;
FIG. 18 is a partial side sectional view of the keg quilt shown in
FIG. 17, along the lines 18--18, showing a center slit and top and
bottom bindings, in accordance with the present invention;
FIG. 19 is a partial sectional view of the keg quilt shown in FIG.
16, along the lines 19--19, with a vertical binding, in accordance
with the present invention;
FIG. 20 is a partial sectional view of the keg quilt shown in FIG.
17, along the lines 20--20, with an opening through the binding and
tube operably connected to a reservoir, in accordance with the
present invention;
FIG. 21 is a partial perspective view of a bottom portion of the
keg quilt in FIG. 16, with pull down straps and a lower binding, in
accordance with the present invention;
FIG. 22 is a partial side sectional view of an embodiment of an
insulative quilt, in accordance with the present invention;
FIG. 23 is a perspective view of an insulated container in a closed
position, in accordance with the present invention;
FIG. 24 is a perspective view of the insulated container in an open
position showing an adjustable floater structure therein, in
accordance with the present invention;
FIG. 25 is a cross sectional view of the insulated container along
lines 25--25 in FIG. 23, in accordance with the present
invention;
FIG. 26 is a partial cross sectional view of the insulated
container in FIG. 25 in the area indicated as item 25, in
accordance with the present invention;
FIG. 27 is a perspective view of a removable and detachable floater
in FIG. 24, in accordance with the present invention; and
FIG. 28 is a perspective view of an alternate embodiment of an
insulated container in an open position showing a plurality of
floaters for seperating, heating or cooling contents in the
insulated container, in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures, a drum and insulative quilt adapted for
insulating a container with temperature sensitive contents from the
surrounding environment is shown.
The drum quilt 10 can include: a substantially tubular open-bottom
body 12 having an open-bottom 14 including a sidewall section 16
and a top section 18 having a slit portion 20; the sidewall 16
includes a predetermined diameter 22 defined as a distance from one
side 24 of the sidewall to an opposite, other side 26; and a
diameter adjusting device 28, whereby the sidewall diameter 22 is
adjustable from a wide diameter position to a narrow diameter
position.
Some of the major advantages of the drum quilt 10, can include the
following. It substantially improves the maintainance of a
consistant temperature inside the drum quilt, and is less subject
to wide temperature variations, as compared to an uninsulated drum.
This structure provides a secure and tight fit to a drum 38, for
improved insulation. A tight fitting quilt 10, can provide an
insulation air pocket and barrier for minimal temperature loss or
exposure to the outside environment. More particularly, the quilt
10 provides an inflatable, air barrier insulation provided by the
body 12, substantially enveloping the drum 38 and contents from the
outside environment. The drum quilt 10 is adjustable to fit
conventional or unconventional (irregular) drum or keg sizes. The
open-bottom 14 provides for simplified installation and
removal.
Additionally, the drum quilt 10 is adaptable to being folded,
placed in a package, and can then be express courriered back to a
desired location, after use, such as by UPS. And, the drum quilt
can be made of a durable material which is adapted to providing
some cushioning around the drum during transportation, as well as
insulation of the drum contents (temperature sensative) from the
elements on a loading dock, or on or in a truck, for example.
In FIG. 1, a fastening belt is shown for attachment to a drum truck
60, for improved transportation and maneuvering of drums.
In one embodiment as shown in FIG. 2, the diameter adjusting device
28 includes at least one outwardly facing interconnectable
structure 30 positioned substantially vertically and extending
substantially from the top 18 to the bottom 14 on the sidewall 16.
A flap section 32 attached to the sidewall 16 can have an inner
portion 34 having an inwardly facing interconnectable structure 36,
adjustably, interconnectable with the outwardly facing
interconnectable structure 30. This structure provides a secure and
tight fit to a drum 38, for improved insulation. A tight fitting
quilt 10, can provide an insulation air pocket and barrier for
minimal temperature loss or exposure to the outside environment.
More particularly, the quilt 10 provides an inflatable, air barrier
insulation substantially enveloping the drum 38 and contents from
the outside environment.
As best shown in FIGS. 2 and 3, the drum quilt 10 can include at
least one of the top 18 and the sidewall sections 16 having a
substantially clear window 40, adapted to receive a document
viewable through the window 40. This structure advantageously
provides a clear plastic window, to view a bill of lading on top 18
and when on the sidewall 16, for presenting a Department of Safety
placard, a MSDS sheet or the like.
Referring to FIG. 6, the top section 18 and sidewall section 16 can
be bound by an upper binding 42, and the open-bottom 14 and
sidewall section 16 can be bound by a lower binding 44. This
structure provides an outwardly extending resilliant (springy),
open-bottom structure for easy placement over and removal from a
drum 38. Additionally, this structure provides improved conformance
to the drum 38, because the bindings 42 and 44 tend to extend
outwardly, and the adjustment structure 28 improves a tight envelop
and insulation barrier around the drum 38.
As best shown in FIG. 7, a substantially vertical sidewall binding
46 can connect the flap 32 with the sidewall section 16, which is
adapted to provide a durable structure, to securely fit around a
wide diameter or narrower diameter drum structure. By connecting
the structure 36 to one of the outwardly facing structures 48 and
50, for example, a tight fit is obtainable. In a preferred
embodiment, the structures 30, 36, 48 and 50 include strips of
interconnectable structures, such as Velcro and the like, for easy
adjustment.
As illustrated in FIGS. 6 and 12-15, the body 12 includes an
interior portion or layer 52, an exterior portion or layer 54 and
an insulative portion or layer 56. Advantageously, each contributes
to the body's durability and resistance to abrasion. A tight
fitting quilt 10 with the desired body 12 construction, can provide
an insulation air pocket and barrier for minimal temperature loss
or exposure to the outside environment. More particularly, a
suitable body 12 construction provides a self-inflatable, air
barrier insulation substantially enveloping the drum 38 and
contents from the outside environment.
In FIG. 6, the drum quilt 10 has a slit portion 20 preferably
positioned on the top 18 adjacent to a portion of the sidewall 16,
adapted to receive a hook portion 58 of a drum truck 60, for
facilitating transportation of a drum with temperature sensative
contents. The placement near the sidewall 16, helps to facilitate
connection and removal of the hook 58, from the slit 20 and drum
38. Another feature of the drum quilt 10, is that the slit 20 has
an automatic closing at rest feature, or self closing feature (when
not in use), to substantially maintain the desired insulation and
temperature in the drum, as shown in FIG. 4.
The slit 20 can include a reinforcement layer or area 60, for
improved integrity. More specifically, the slit portion 20 and
reinforcement area 62, include a normally closed condition
(action), to allow manipulation of the drum 38 in use during
transportation, and will spring back closed after removal of the
hook portion 58 of the drum truck 60.
In FIG. 8, the sidewall section 16 has an open-side portion 64, for
simplified placement and removal in certain applications.
As shown in FIG. 9, the sidewall section 16 can include one or more
interconnectable structures which are adjustably connected, for
simplified diameter adjustment. This structure can accommadate one
of many different diameters and configurations, ie. two or more
different diameter drums or kegs, for example.
In a preferred embodiment, the sidewall section 16 includes at
least one substantially adjustable securement device, substantially
as shown in the figures. More particularly, the securement device
can include a plurality of strap and ring securement devices,
substantially as shown in FIG. 9.
In this embodiment, four equi-spaced securement devices, identified
as items 66, 68, 70, and 72, are shown securely attached, such as
sown directly to the sidewall section 16. This embodiment provides
independant adjustment along various heights, for improved
insulating and enveloping around the drum. Moreover, the strap and
ring securement devices 66, 68, 70, and 72, provide for: (i)
improved securement; (ii) ease of adjustment for a tighter and a
firmer fit to a drum; and (iii) an improved system of insulating
the temperature sensitive material in a keg, drum, container or the
like. Additionally, the drum quilt 10 provides a self inflating air
pocket and barrier, for further insulation between the temperature
sensitive contents and the outside environment.
The diameter adjusting devices 66, 68, 70, and 72, include a number
of vertically spaced belts and adjacent loops for individual
adjustment of the diameter of the sidewall section, to accomodate
standard or irregularly configured drums. More specifically, a
first securement device 66 includes a first strap 74 with proximal
and distal interconnectable structures 76 and 78, and adjacent
anchor ring 80. The second securement device 68 includes a second
strap 82 with proximal and distal interconnectable structures 84
and 86, and adjacent second anchor ring 88. The third securement
device 70 includes a third strap 90 with proximal and distal
interconnectable structures 92 and 94, and an adjacent third anchor
ring 96. And finally, the fourth securement device 72 includes a
fourth strap 98 with proximal and distal interconnectable
structures 100 and 102, and adjacent fourth anchor ring 104. The
securement devices are generally sewn or appropriately attached to
the sidewall 16.
In a preferred embodiment, the securement devices 66, 68, 70 and
72, comprise Velcro, which is a commonly known interconnectable
material. However, other structures can be used, such as but not
limited to snapable belts, zippers, button and hole arrangements,
and the like, as should be appreciated by those skilled in the
art.
In FIG. 10, a top view of the drum quilt 10 in FIG. 9 is shown,
with a window 40, center seam 106 and slit 20, for simplified
replacement, in the event of damage to the top section 20. Another
benefit to the drum quilt10, is that it is substantially modular or
made with replaceable components, for ease assembly and/or
replacement and repair of component parts, if needed.
In FIG. 11, a cross-sectional view of a bottom portion 108. It can
be made of an insulative material for improved insulation. Also,
the bottom portion is adapted to minimize damage to the bottom of a
drum when abruptly set down, for example. The bottom 108 is
configured to receive a substantially conventionally shaped drum in
an upperwardly facing receptacle section 110. In one embodiment,
the bottom 108 comprises recycled tires or rubber.
Referring to FIGS. 12-15, various body 12 and insulative quilt
constructions are shown. In FIG. 12, a single trip, substantially
recyclable body construction is shown, as detailed previously, with
interior layer 52, exterior layer 54 and insulative layer 56.
In a preferred embodiment, the body 10 includes: an interior layer
52 comprising a coated spun bonded polypropelene, preferably Typar
model 3153 from Reemay; an exterior portion or layer 54 also
comprising the same as above (a coated spun bonded polypropelene,
preferably Typar model 3153 from Reemay); and an insulative portion
56 comprising a polypropelene, polyester, or the like, preferably a
Dupont 808 material, also known as Hollofil. This is believed to be
made of a polypropelene material. This construction provides for
improved consistancy and self-inflatable body structure, after
being crushed and folding during its life. The combination provides
a self-forming and resilient, configuration and structure, which
helps to keep the temperature sensitive material warm, hot or cold,
as desired.
More specifically, the insulative portion 56 can comprise a
plurality of individual layers of materials, for improved isolation
of the temperature sensitive material from the environment.
In FIGS. 13 and 15, a multi-trip, (commonly referred to as
therma-grade construction), multi-layer construction 120, body 12
is shown. This therma-grade construction 120 can vary widely. In a
preferred embodiment, the individual layers include a first layer
122, preferably of a vinyl coated polyester or nylon, most
preferably Imperial 600 from Nassimi Corp., in N.Y., N.Y.; second
and fourth layers 122 and 128 of preferably a spun bonded material
such as Typar; a third layer 126 of a holofil or spun bonded
material, most preferably a Dacron Dupont 808 polyester material;
and a fifth layer 130 comprising a coated polyester, such as a
vynal coated nylon, such as Imperial 200 from Nassimi Corp. This
construction provides a durable, self inflatable and resilient
(springy) body 12, for improved placement and removal.
In FIG. 14 and 15, a seven layer body construction 140, is shown
with layers 142, 144, 146, 148, 150, 152, and 154, from the
exterior to interior layers. In a preferred embodiment, the
individual layers include a first layer (exterior) 142 and seventh
interior layer 154, each comprising a vynal coated polyester,
preferably Imperial 600 (denier) and vynal coated nylon material
preferably Imperial 200, respectively; the second layer 144, fourth
layer 148 and sixth layer 152 can comprise a spun-bonded or Typar
material; and the third and fifth layers 146 and 150, can comprise
a spun bonded material or holifil, preferably Dacron Dupont 808
polyester holifil, for providing a recycleable drum quilt, which
can contribute to saving fuels and the like, by improved
insulation.
The multi layer constructions provide improved insulation, and self
inflating constructions which facilitate placement and removal,
because of the resillient nature of the body 12, made with these
constructions. A Nylon interior layer helps to facilitate placement
on a drum, and a Vynal outer layer provides a durable exterior.
In one embodiment, pull down means, preferably in the form of
opposite and interior pull-down straps 112 are utilized, as shown
in FIGS. 5 and 8, for facilitating placement over a drum or keg,
for example.
Thus, the drum quilt 10 is particularly adapted for insulating a
container with temperature sensitive contents from the surrounding
environment. In one application, it includes: a substantially
tubular open-bottom body 12 having an open-bottom 14 including a
sidewall section 16 and a top section 18 having a slit portion 20;
the sidewall 16 includes a predetermined diameter defined as a
distance from one side 24 of the sidewall to an opposite, other
side 26; and a diameter adjusting device (securement device) as
shown in the figures, whereby the sidewall diameter is adjustable
from a wide diameter (at rest) position to a narrow (pulled taunt)
position.
In FIGS. 16-21, a drum quilt in the form of a keg quilt 210, is
shown. It is adapted for insulating a container/keg 238 with
temperature sensitive contents, such as pop or beer from the
surrounding environment. It can comprise: a substantially tubular
open-bottom body 212 having an open-bottom 214 including a sidewall
section 216 and a top section 218 having a slit portion 220; the
sidewall 216 includes a predetermined diameter defined as a
distance from one side 224 of the sidewall to an opposite, other
side 226; and a substantially upwardly extending, upper binding 242
having a port 243 connectable to a resevoir 247 for receiving
liquid.
In one embodiment, the open-bottom 214 and sidewall section 216 are
bound by a lower binding 244. The keg quilt 210 contributes to
minimizing waste by catching spilled liquid. The outer layer can
include a substantially reflective layer to reflect the sunlight
and the like, for improved insulation. The difference between the
drum quilt in FIG. 1 and the keg quilt 210, is the placement of the
slit 220 in a substantially middle portion of the top section, and
preferably includes first and second interconnectable sections 221
and 223 to adjustably close the slit 220, to maximize insulation.
Most of the rest of the keg quilt 210 is substantially similar to
the structure of the drum quilt 10, and thus the item numbers are
similar but include two hundred, for simplicity (ie. drum quilt 10
and keg quilt 210, etc.) In FIGS. 12-15 and 22, various embodiments
of an insulative quilt body are shown.
The insulative quilt body in its simplest form, can comprise:
interior and exterior layers having a coating of at least one of
polypropylene and polyester; an insulative portion comprising a
batt of staple fibers being sandwiched between inside sides of the
interior and exterior layers; and a binding structure along
perimeter edges of the interior and exterior layers securing the
insulative portion therebetween. This construction is a cost
effective improvement to insulate and minimize temperature
fluctuations of temperature sensitive materials.
In one embodiment, the insulative portion or batt of staple fibers
comprises a layer of at least one of spun bonded material and
Hallofil placed between the interior and exterior layers to provide
a predetermined thickness and density, to provide a desired
insulation. Moreover, the batt of staple fibers herein provides a
self-inflatable construction for improved insulation. It is
believed that the insulative portion or batt of staple fibers
includes a plurality of fibers each with hallow portions that trap
air. Additionally, the batt also has air between each fiber. Thus,
this construction provides at least two individual air pockets or
insulation barriers made of air.
The exterior layer can include a substantially clear window adapted
to receive a document viewable through the window. The window could
include a shiping destination document, for example.
In a preferred embodiment, the interior and exterior layers
comprise a coated, spun bonded material, the coating comprising at
least one of polypropylene and polyester. The coating provides a
substantially air-tight construction, for good self-inflating
properties and improved insulation. In more detail, the interior
and exterior layers comprise at least one layer of Mylar, Nylon and
Vinyl, for a cost effective and suitable air-tight
construction.
The body includes an interior portion, an exterior portion and an
insulative portion, which comprise durable materials that can
substantially withstand abrasion and severe environments. Various
costructions are possible, depending on the application and
requirements.
In one body construction, between the insulative portion and the
interior and exterior layers are intermediate layers of a spun
bonded material, defining a five or more layer construction, for
improved durability and resiliance (or a springy construction).
In one example, the insulative portion comprises one or more layers
of a spun bonded material and one or more layers of a polyester
Hallofil or generic Hallofil material, depending on the desired
density and insulation properties. The term Hallofil is a term of
art and has its ordinary meaning. In a preferred embodiment, the
Hallofil is Dacron Hallofil polyester 808/908 from DuPont. It
should be understood that other Hallofils may be used depending on
the requirements and specifications.
In a preferred embodiment, an insulative quilt body is constructed,
to substantially enclose a body with a temperature sensitive
material. The body can include: a first and a second cell each
including: interior and exterior layers comprising spun bonded
material each having a coating of at least one of polypropylene and
polyester; an insulative portion comprising a batt of staple fibers
of at least one of a spun bonded material and Hallofil material
being sandwiched between the interior and exterior layers; and a
binding structure comprising a seam along perimeter edges of the
interior and exterior layers securing the insulative portion
therebetween, defining a multi-layer insulative quilt body.
Adventageously, this construction can provide two insulative and
substantially springy, uniform, and resilient constructions. More
specifically, each cell can define a self-inflatable and
substantially springy insulation body.
In one embodiment, the batt of staple fibers includes a
substantially intimate blend of fibers with a substantially
consistant and uniform density. This contributes in providing a
substantially springy, and more uniform construction. More
particularly, each of the cells is substantially self-inflatable
and provides at least some independent insulation.
More specifically, there are two preferred processes by which
polyester high loft insulation can be stabilized. The first is
spray bonding. A bonded batt is produced by polyester batting being
sprayed with a resin (glue) and then dried typically in a three
pass oven. On thicker battings, the spray may not fully penetrate
into the middle of the batting, resulting in much of the resin
laying on the exterior surfaces of the batting. This can create a
stiffer, harder to mold batting. The middle fibers, can become
unstabilized prematurely, which means they can loose their loft and
some insulation properties prematurely.
The second process involves the use of intimate blend of fibers
with different melting temperatures. For example, taking fibers
that melt at low temperatures with regular fibers that do not melt
at such low temperatures a more intimate batt can be produced. When
this batting enters a one pass oven, the low melt fibers liquify,
and flow over the other regular fibers, and when they leave the
oven they cool down and solidify. This process provides a strong
bonding between the two different fibers in the middle as well as
the surfaces. The use of an intimate blend of fibers can provide a
more resilient and better insulative material than the spray bonded
process. In a preferred embodiment, the intimate blend of fibers
include a high quality Dacron Hallofil polyester Hallofil 808/908,
which is made as detailed above, and it can be purchased from
DuPont. It is particularly adapted for use in insulative quilts as
detailed herein, which demand a high level of performance.
The interior and exterior layers comprise a coating of at least one
layer of Mylar, Nylon, polyester, polypropylene and Vinyl, for
providing a substantially air-tight construction, for improved
insulation.
In one preferred embodiment, the first and second cells are
substantially independant of each other and define at least a six
layer construction which are simply two cells adhesively or
suitably attached together. In another preferred embodiment, the
first and second cells are substantially independant of each other
and can define at least an eight layer construction. These
constructions are particularly adventageous when used in connection
with, but not limited to, drum quilts, pallet quilts, cargo quilts
and the like.
Insulated Container
In its simplest form, an insulated delivery container 500 is shown
in FIGS. 23-28, for insulating temperature sensitive contents from
the surrounding environment. The container 500 can include: a body
502 including a sidewall section 504, a top section 506 and a
bottom section 508 having at least one of an open-top 510 and
open-sidewall 512; a door 514 pivotably connected to the body 502
for providing an open position for loading and unloading and a
closed position for insulating contents therin, defining an
enclosure; and a temperature control floater 516 for at least one
of sealing temperatures in the enclosure and deviding the enclosure
into at least two compartments, couplable to the body 502.
The container 500 provides the advantages of being portable, light
weight and easy to carry and made of duarable, washable and long
lasting materials, and is particularly adapted to transport all
hot, chilled or cold or two of the three in the same container. As
should be understood, two or more temperature control floaters
(hereafter interchangably referred to as floater or temperature
control floater or device) can be used. In this embodiment, three
tempered items can be stored in the same container 500, with each
enclosure in the container being defined by the dimensions of the
container and each floater. For example, with two floaters three
different tempered items ie. hot, chilled and cold, can be stored
and transported, maintaining the desired temperatures for each
tempered item for hours. The container 500 has many uses, and is
particularly useful in the food, transportation and medical
industries.
The body 502 in proximity to at least one of the open-top 510 (FIG.
24) and open-sidewall 512 (FIG. 28) includes an outwardly facing
interconnectable structure 518 and the door 514 includes a flap
section 520 attached to at least a portion of an outer periphery of
the door 514 having an inner portion having an inwardly facing
interconnectable structure 522, interconnectable with the
TABLE 1 ______________________________________ Title: UNICARGO MLI
PILLOWS ______________________________________ Inf. Requested:
THERMAL CONDUCTIVITY Apparatus: HEAT FLOW METER Test Method:
ASTM-C-518 ______________________________________ Results THERMAL
THICK- CONDUCTIVITY NESS DENSITY (BTU-in/hr-ft.sup.2 -.degree. F.)
SAMPLE (inches) (pcf) 10.degree. F. R-VALUE
______________________________________ T0001 0.250 3.86 0.240*
1.040 T0002 1.150 1.37 0.268 4.284 T0003 1.500 2.35 0.244 6.153
T0004 1.500 1.34 0.267 5.620 T0005 2.000 2.23 0.237 8.444 T0006
2.000 1.25 0.264 7.589 T0007 2.250 2.57 0.229 9.832 T0008 1.500
3.53 0.247 6.066 T0009 1.800 2.67 0.248 7.271 T0010 0.850 3.98
0.227 3.740 T0011 0.185 15.13 0.309* 0.599
______________________________________ *Comments: Except for
samples T0001 and T0011, all the tests were run with a mean
temperature of approximately 10.degree. F. and a hot face
temperature at or just above 32.degree. F. Due to their relatively
thin nature and the limitations of our machines, samples T0001 and
T0011 were unable to hold the same .DELTA.T as the others.
Therefore the cold side was approximatel 10 degrees (mean temp. 5
degrees) warmer in order to keep the hot face at 32.degree. F.
TABLE 2 ______________________________________ Title: UNICARGO MLI
PILLOWS ______________________________________ Inf. Requested:
THERMAL CONDUCTIVITY Apparatus: HEAT FLOW METER Test Method:
ASTM-C-518.sup..dagger-dbl. ______________________________________
Results THERMAL THICK- CONDUCTIVITY NESS DENSITY
(BTU-in/hr-ft.sup.2 -.degree. F.) SAMPLE (inches) (pcf) 75.degree.
F. R-VALUE ______________________________________ T0001 0.250 3.86
0.296 0.844 T0002 1.150 1.37 0.332 3.468 T0003 1.500 2.35 0.301
4.977 T0004 1.500 1.34 0.328 4.573 T0005 2.000 2.23 0.298 6.711
T0006 2.000 1.25 0.337 5.936 T0007 2.250 2.57 0.286 7.862 T0008
1.500 3.53 0.299 5.018 T0009 1.800 2.67 0.306 5.876 T0010 0.850
3.98 0.272 3.125 T0011 0.185 15.13 0.355 0.521
______________________________________
outwardly facing interconnectable structure 518 of the body 502.
This structure defines a closure system. In a preferred embodiment,
upon completion of packing the container 500, the flaps 520 are
suitably pulled down completely, to secure the structure 522 of the
flaps 520 firmly against the corresponding outwardly facing
interconnectable structure 518, both preferrably Velcro, for
maintaining the desired temperature in the container 500 for a
desired period of time.
In a preferred embodiment, the inwardly and outwardly facing
interconnectable structures 522 and 518 comprise narrow strips of
Velcro, for simplified opening and closing. Also, at least one of
the inwardly and outwardly facing interconnectable structures 522
and 518 include rigidizers, as shown in FIG. 26, as item 524, to
provide a substantailly flat surface for improved sealing.
As shown in FIG. 25, the floater is complementarily configured to
be sucurely received in the container 500. In a preferred
embodiment, the floater 516 includes an internal rigidizer 526, to
provide a tight and secure fit within the container 500.
As shown in the FIG. 24, peripheral portions of the door, sidewall
and bottom section are bound, as items 528, 530 and 532. These
bindings contribute to providing the desired insulation and nearly
air tight desired construction.
Referring to FIGS. 25 and 26, the floater 516 is shown pivotably
coupled 534 to the body 502, for ease of adjustment, loading and
unloading. In FIG. 26, the floater 516 is detachably coupled 536 at
one end 538, to the body 502, for certain applications and ease of
cleaning and adjustment. At the other end of the floater 516 a loop
may be included, to facilitate handling and adjustment of the
floater 516.
As shown in FIG. 25, the body 502 and door 514 include an interior
portion 540, an exterior portion 542 and an insulative portion 544,
for providing the desired insulation and asthetics.
The temperature control floater 516 contributes to minimizing loss
of heat or cold depending on the application, and further helps to
maintain a desired temperature for a longer period of time by
seperating the tempered air space form a non-tempered air space.
Thus, the smaller the tempered air space is (where the temperature
sensitive materials are stored in the container 500), the longer
the desired temperature will tend to remain. In addition, during
loading and unloading of temperature sensitive materials in the
container 500, the floater 516 provides a light weight insulation
door that can be easily opened and closed, as desired, while
maintaining and preserving the desired temperature in a tempered
area (where the temperature sensitive materials are stored) in the
container 500. Thus, the user does not have to open and close the
open-top 510 or open-side 512 during loading, for example.
The containers shown in FIGS. 23 and 28, can be used to carry
various materials, and are particularly adapted for use in
connection with temperature sensitive materials, chemicals, and the
food and medical industries, for example. The container 500 in FIG.
28, is adapted for use with flat materials, foods and the like,
such as a lightweight pizza carrier.
In one embodiment, a light weight carrying tray, preferably a
polymeric coated (ie. Michem coated) card board with a series of
heat (or cool) exchange ports, is used for improved dense loading
in the container.
In one embodiment, the floater 516 is a passive element defining an
additional insulation layer, or an active element providing a heat,
chill or cold source. As used herein, passive element means that
the floater is free of a temperature source, and active element
refers to a floater with a compartment, pocket or the like for
helping to provide a desired temperature in proximity thereto. For
example, the floater could include a pocket or enclosure for
holding hot, cold or chill elements or sources, phase change
materials, and the like. For example, when used in the food
industry, cold drinks could be stored in the bottom below the
floater 516 and hot hamburgers and fries above.
In another embodiment, the interior of the container 500 can
include compartments, pockets and the like, for holding ice,
packages of phase change materials, etc., for providing a desire
temperature in the container. For example, in a preferred
embodiment, one or more packages 554 of phase change materials can
be placed in a pocket 556 in an interior sidewall or floater, for
preserving a desired temperature for a longer period of time, as
shown in FIG. 25.
As used herein, a phase change material (PCM) refers to materials
that reversably absorb and release heat at a constant temperature
during melting and freezing. PCMs have been used over the years and
can be obtained from Phase Change Laboratories in San Diego, Calif.
PCMs can be obtained for hot and cold medical therapy and food
serving ware, for example. A package of PCMs generally include
water and silica dry powder for cold medical therapy. The
water/silica dry powder is charged (frozen) by placing the package
containing the dry powder in a freezer compartment of a
refrigerator for two to four hours prior to use. The powder remains
soft and conformable even after freezing.
In more detail, these water/silica powders make use of high latent
heat of fusion and crystallization of water (80 calories/gram) and,
therefore can supply cold temperatures at about zero degrees
centigrade for several times as long as liquid water and gels on
the market that use the much lower sensible heat of water (one
calorie/gram/degree centigrade), according to the literature.
PCMs can be used as hot or warm supplies as well. For example, a
hot package can be charged by heating for about four minutes in a
conventional microwave oven. Likewise, hot packages of dry powders
also remain conformable above and below use temperature. As should
be understood, these PCM are preferred, and other similar
temperature sources or active temperature elements are availabe as
hot, chill or cold sources, and can be used in connection with this
invention.
As shown in FIGS. 23 and 24, the body 502 includes reinforcement
sections 546, preferably in the form of straps, at least partially
around the body 502 and handles 548 connected thereto, to simplify
carrying. More particularly, the handles 548 are adjustable
carrying straps, which can include an extended position 550
providing dual shoulder straps and a retracted position 552 adapted
to provide independent handles (carrying straps), for carrying
heavier loads.
As detailed herein with respect to the insulative body, the body
502 can include: interior and exterior layers 540 and 542 having a
coating of at least one of polypropylene and polyester; an
insulative portion 544 comprising a batt of staple fibers being
sandwiched between inside sides of the interior and exterior
layers; and a binding structure 528, 530 and 532 along perimeter
edges of the interior and exterior layers 540 and 542 securing the
insulative portion 544 therein. In one embodiment, the batt of
staple fibers comprises a layer of at least one of spun bonded
material and Hallofil. This construction provides a light weight
yet effective insulated container for many applications. In a
preferred embodiment, the interior and exterior layers 540 and 542
comprise a coated, spun bonded material, with the coating being
polypropylene, polyester, blends thereof and the like. For example,
the interior and exterior layers 540 and 542 comprise a layer of
Mylar, Nylon, polyester, Vinyl or the like.
In certain applications, between the insulative portion 544 and the
interior and exterior layers 540 and 542 are intermediate layers of
a spun bonded material, defining at least a five or more layer
construction. This construction can provide a desired insulation
value, while being light weight. For example, the insulative
portion 544 can include one or more layers of a spun bonded
material, one or more layers of a polyester Hallofil material and
the like.
In a preferred embodiment, the batt of staple fibers includes a
substantially intimate blend of fibers with a substantially
consistant and uniform density, for improved insulation. Thus, when
appropriately constructed, the body 502 and door 514 include a
self-inflatable and substantially springy insulation layer.
In a preferred embodiment, the insulative body 502 can comprise:
interior and exterior layers having a coating of at least one of
polypropylene and polyester; an insulative portion comprising a
batt of staple fibers being sandwiched between inside sides of the
interior and exterior layers; and a binding structure along
perimeter edges of the interior and exterior layers securing the
insulative portion therebetween. This construction is a cost
effective improvement to insulate and minimize temperature
fluctuations of temperature sensitive materials.
In one embodiment, the insulative portion or batt of staple fibers
comprises a layer of at least one of spun bonded material and
Hallofil placed between the interior and exterior layers to provide
a predetermined thickness and density, to provide a desired
insulation. Moreover, the batt of staple fibers herein provides a
self-inflatable construction for improved insulation. It is
believed that the insulative portion or batt of staple fibers
includes a plurality of fibers each with hallow portions that trap
air. Additionally, the batt also has air between each fiber. Thus,
this construction provides at least two individual air pockets or
insulation barriers comprising air.
The exterior layer can include a substantially clear window adapted
to receive a document viewable through the window. The window could
include a shiping destination document, for example.
In a preferred embodiment, the interior and exterior layers
comprise a coated, spun bonded material, the coating comprising at
least one of polypropylene and polyester. The coating provides a
substantially air-tight construction, for good self-inflating
properties and improved insulation. In more detail, the interior
and exterior layers comprise at least one layer of Mylar, Nylon and
Vinyl, for a cost effective and suitable air-tight
construction.
The body includes an interior portion, an exterior portion and an
insulative portion, which comprise durable materials that can
substantially withstand abrasion and severe environments. Various
costructions are possible, depending on the application and
requirements.
In one body construction, between the insulative portion and the
interior and exterior layers are intermediate layers of a spun
bonded material, defining a five or more layer construction, for
improved durability and resiliance (or a springy construction).
In one example, the insulative portion comprises one or more layers
of a spun bonded material and one or more layers of a polyester
Hallofil or generic Hallofil material, depending on the desired
density and insulation properties. The term Hallofil is a term of
art and has its ordinary meaning. In a preferred embodiment, the
Hallofil is Dacron Hallofil polyester 808/908 from DuPont. It
should be understood that other Hallofils and insulative materials
and constructions may be used, depending on the requirements and
specifications.
In a preferred embodiment, the container 500 includes a Mylar
interior layer 540 and Mylar exterior layer 542 off 600 denier
polyester block, and an insulation portion 544. The insulative
portion comprises:
(i) a first cell comprising a layer of Typar, fiber with a density
of one, one and a half or two ounces, depending on the required
specifications, and another layer of Typar, sown (or suitably
attached) together; and a second cell of the same, each of the two
cells sown (or suitably attached) together; or
(ii) one cell comprising two layers of Typar with a fiber
sandwiched therebetween, the fiber having a density of one, one and
a half or two ounces, sewn together at the outer peripheries.
COMPARATIVE EXAMPLES
All of the tests involved using approximately a one foot square
swatch of material, exposing it to various temperatures and
recording the results, as shown in Tables 1 and 2.
Comparative Example 1 in the tables, included a conventional bubble
pack with reflective foil on one side.
Example 2 included three layers, specifically Typar, a Dacron
Hallofil polyester 808/908 one ounce density, and Typar.
Example 3 included two cells of the sample in Example 2. More
specifically, this sample included a first cell of Typar, Dacron
Hallofil polyester (DuPont 808/908) and Typar, and a second cell of
Typar, Dacron Hallofil polyester (DuPont 808/908) and Typar sewn
together to form a swatch. This construction is referred to as an
Ultra Therma construction.
Example 4 included three layers, specifically Typar, a Dacron
Hallofil polyester 808/908 one and a half ounce density, and
Typar.
Example 5 included the Ultra Thermal construction in Example 3,
with two layers of a more dense or one and a half ounce density
Dacron Hallofil polyester 808/908.
Example 6 included a similar construction as in Example 4, but with
a two ounce density for the Dacron Hallofil polyester 808/908.
Example 7 included the Ultra Thermal construction in Example 5,
with two layers of a more dense or two ounce density of Dupont
808/908.
Example 8 included the same construction as in Example 3, and
further included two 600 denier polyester black and Mylar outer and
inner coatings, respectively, defining a five layer
construction.
Example 9 included the same construction as in Example 6, and
further included two 600 denier polyester black and grey outer and
inner coatings, respectively, defining a five layer
construction.
Comparative Example 10 included a four layer swatch of Nylon,
bubble pack with foil, sponge foam of about one inch in thickness
and Nylon.
Comparative Example 11 included a three layer swatch of Nylon,
bubble pack and Nylon.
As shown in Examples 2-9, improved R values (insulation values) can
be achieved with the constructions detailed herein.
Although various embodiments of the invention have been shown and
described, it should be understood that various modifications and
substitutionns, as well as rearrangements and combinations of the
preceding embodiments, can be made by those skilled in the art.
* * * * *